asq austin sec. 1414 october 10, 2018 michael brucker · qual to aec-q100 and full support of apqp...
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ASQ Austin sec. 1414 October 10, 2018 Michael Brucker
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What Will I Learn Today? Automotive Service and Zero Defects
1. Participating in the Auto supply chain is more than
AEC grade qual and IATF 16949 registration
2. As a supplier, you must develop a culture of serving
Automotive Tier 1s and OEMs
3. The AEC Q004 Zero Defects Guideline is a
jumpstart on developing that culture and can be
used to support any industry segment
4. Mike Brucker is older than his LinkedIn picture would
indicate
GLOBALFOUNDRIES Confidential 2
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Who am I? Michael Brucker, Sr Mgr of Automotive Systems, GlobalFoundries
ASQ Certified CQM/OE, CQE, CQA
Proud parent of the AutoPro™ Service Package
20+ years of related experience including leading key initiatives for
GlobalFoundries, Silicon Labs, Motorola, and Texas Instruments
Contributing member to the AEC Q004 Zero Defects Guideline
Husband to Linda (Sales Director for Kate Farms Medical)
Dad to Connor, Junior Economics major at UT Dallas and
Dylan, Sophomore at St. Michael’s, majoring in Football and Xbox 360
Defensive Coordinator for St. Gabriel’s Middle School Lacrosse
Founder, lead singer, sax and harmonica player for Sader Dads Rock band
Pursuing MS in Quality Engineering Management from E. Michigan U.
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Changing Automotive Landscape GlobalFoundries AutoPro™ Service Package
Acceleration of Electronics solutions within Automotive
Promise to enhance the driving experience (navigation, remote roadside
assistance, and semi- and autonomous driving)
ICs need to combine data from multiple sensors with high-performance
processors that make control decisions
GlobalFoundries, the fastest growing auto foundry in the world, built its
AutoPro™ Service Package upon 3 foundational pillars:
• Quality Systems Readiness
• Technology Platform Readiness and
• Operational Readiness
Automotive Electronics Council (AEC) and Q004 Zero Defects Guideline
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What is the GF AutoPro™ Service Package? How GlobalFoundries does Automotive
Automotive customers expect the highest levels of quality and reliability - in
technology, in manufactured products, and in service and support
The GF approach is to develop robust systems to acknowledge all customer
requirements and industry expectations (such as AEC and IATF) and to
standardize these systems across all factories and business groups
GLOBALFOUNDRIES Confidential 5
The AutoPro Service Package defines
these systems with three organizational
pillars that serve as the foundation for
our customer relationships
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All GLOBALFOUNDRIES AutoPro
sites driving to zero defects!
© 2017 GLOBALFOUNDRIES 6
AutoPro™ Service Package Three Foundational Pillars
Customer Relationship Management
Quality Systems Technology Platform Operational Control
Global Standard Quality Handbook Advanced Product Quality Planning Enhanced Outgoing Quality Controls
Change Mgt and PCN Horizon Reports Customer Critical Parameter Tracking Lot Control and Maverick Handling
Zero Defects Culture DFMEA & PFMEA and ASIC Design Preferred Tool Path Mgt
Supplier and Sub-supplier IATF Mgt AutoPro Reliability Monitoring Fault Detection and Classification
Core Tools Execution ISO26262, ASIL and Functional Safety Post Maintenance Control
VDA 6.3 Process Approach AutoPro Design Rules and DFM Automated SPC
IATF 16949 Registration AEC Q100 Qual (Grade 2,1,0) Safe Launch Methodology
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AutoPro™ Quality Systems Highlights Focus on Risk Management throughout the process
All factories transitioned to IATF* 16949:2016 registration [*International
Automotive Task Force]
Corporate and Site Automotive Steering
Committees address automotive business
strategy and performance; includes Executive
leadership from Business, Manufacturing,
Product Development and Quality
Supplier & sub-suppliers are managed using
IATF 16949 requirements
Customer expectations supported by a Zero
Excursion, Zero Defect approach
Fab 7 & GIGA+ Singapore
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AutoPro™ Technology & Design Highlights Qual to AEC-Q100 and full support of APQP
AEC Grade based on customer mission profile and product line technology
roadmap; foundation IP qualified to AEC-Q100 up to Grade 0 (Grade 2 is
standard offering)
Design Risk Assessment
• IC Design: includes FMECA, FTA, DFMEA, DFM/DFT
• Wafer Fab: includes FMEA and 3x5 Why per customer DFMEA
Mandatory AutoPro Design Rule Checks and Design for Mfg checklist
before Tapeout
Product roadmap and process longevity to meet automotive market needs
GLOBALFOUNDRIES Confidential 8
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GF AutoPro™ Safe Launch Highlights Safe Launch driven by GF’s Release to Production process
Increased inline metrology and defect
density inspection sampling and
electrical and reliability monitoring
based on risk assessment
Fab1 Dresden
GLOBALFOUNDRIES Confidential 9
Aligns with Automotive APQP (Advanced Product Quality Planning) and
customer DFMEA
Risk assessment and Lessons Learned-based improvement plans
Extended validation of critical process steps
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GF AutoPro™ Automated Mfg Control Highlights Error-proofed Automation support of Production
Product designation invokes Lot Identification and AutoPro controls
Preferred Tool Path and enhanced tool control including automotive lot
restriction subsequent to tool maintenance and repair
Measurement System Analysis and tighter Statistical Process Control
(greater sampling, CpK 1.67 for CTQs) based on Tool and Process FMEAs
Control plan-based, automated Lot Hold, and Maverick Lot identification
GLOBALFOUNDRIES Confidential 10
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GF AutoPro™ Mfg Control Highlights
Designated AutoPro Production based on APQP
Special OCAPs, Restricted process
rework
Increased inline defect density
inspection
Reliability and DPPM monitoring
exceeding commercial product
Fab8 Malta NY
GLOBALFOUNDRIES Confidential 11
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GF AutoPro™ Service Highlights
Automotive market means AutoPro Support
PPAP capability and support
Automotive Change Management and Horizon Reporting
Prioritized Failure Analysis; Corrective Actions using 8D
methodology with 24 hour containment
Continual Improvement plans in support of customer expectations
GLOBALFOUNDRIES Confidential 12
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AEC Qualification to Grade 0, 1, 2, 3
Sites certified to IATF 16949
Product Development per APQP
Automated Manufacturing controls
based on a zero defects culture
GF AutoPro™ Service Package Summary
Integrated into the OEM Supply Chain
GLOBALFOUNDRIES Confidential 13
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What is the AEC? Automotive Electronics Council History
Created at a JEDEC meeting in 1992 when Delco
(GM) and Chrysler discussed the idea of common IC
qualification specifications; Ford later invited
Test Qualification for Integrated Circuits defined in
AEC Q100, which documented the preferred
qualification for Chrysler, Delco, and Ford
Following this initial start, qualification specifications
for other part categories were developed
AEC hosts an annual Reliability Workshop
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Zero Defects Guideline Q004 Introduction
A set of tools and processes suppliers and users of integrated circuits can
use to approach or achieve a goal of zero defects during a product's lifetime
This guideline makes suggestions for when each of these tools and methods
should be used depending on the application or business case
This is not to used as a requirements document, but a tool box of methods
As a part and/or process is optimized and matures over time, less tools are
needed to improve or maintain quality and reliability
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AEC Home Page [aecouncil.com] AEC Documents
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AEC Documents AEC - Q004 Zero Defects Guideline
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Zero Defects Design Tools From DFMEAs to Simulation and Characterization
3.1 Failure Mode and Effect Analysis DFMEA
3.2 Redundancy
3.3.5.2 Built-in Self Test
3.4.5.1 Design for Test
3.5.8.1 Design for Analysis
3.6 Design for Manufacture
3.7 Design for Reliability
3.8 Simulation
3.9 Characterization 18
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Zero Defects Manufacturing Tools From PFMEAs to Control Plans
4.1 Process FMEA
4.2 Statistical Analysis of Variance
4.3 Control Plan
4.4 Statistical Process Control
4.5 Internal Audits
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Zero Defects Test Tools From Statistical Controls to Data Management
5.3 Process/Part Average Testing
5.4 Statistical Bin Yield Analysis
5.5 Data Collection, Storage and Retrieval
5.6 Screens
5.7 Lot Acceptance Gates
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Zero Defects Capabilities Tools From Industry-Specific Tests to Industry Standards
6.1 Stress-Strength Analysis
6.2 Data Analysis
6.3 Industry Standards
6.4 Environmental Stress Testing
6.5 Part Derating
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Zero Defects Improvement, Problem Solving Tools From Continual Improvement to Test/QC Monitoring
7.1 Wafer Level Fail Mechanism Monitoring
7.2 Process/Product Improvements
7.3 Production Part Monitoring
8.2 Problem Solving Techniques
8.3 Failure Analysis Process
8.x Six Sigma Approach
8.x Lean / Kaizen Approach
9.1 System Engineering
9.2 Quality Function Deployment
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What’s in Your Toolbox? And where do you get more useful & better tools?
Systemic approach
Process approach
Risk-Based thinking
Benchmarking (societies like ASQ and AEC)
Know your standard Quality tools (Fishbone diagrams, Pareto charts, SPC,
DOE, Brainstorming, etc.)
Get ASQ certified!
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The Culture of Automotive This is not your father’s Oldsmobile
AEC Qualification & IATF 16949 Registration
Zero Defect Approach
Commitment to service and support
Continual improvement and cost reduction
Trust relationship
Must bring value beyond supplied product
Result is long-term customer commitment!
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What Did I Learn Today? Automotive Service and Zero Defects
1. Participating in the Auto supply chain is more than
AEC grade qual and IATF 16949 registration
2. As a supplier, you must develop a culture of serving
Automotive Tier 1s and OEMs
3. The AEC Q004 Zero Defects Guideline is a
jumpstart on developing that culture and can be
used to support any industry segment
4. Mike Brucker is indeed older than his LinkedIn
picture would indicate
GLOBALFOUNDRIES Confidential 25
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Final Word Really, this is the last slide
Don’t sacrifice the important for the urgent!
Have a plan
Stay connected
Communicate
Value people, what they bring, and leverage their contribution
Keep learning
GLOBALFOUNDRIES Confidential 26